AWARENESS OF 5S IMPLEMENTATION IN INDUSTRIES.

1. 5 “S” Training Module

2. What is 5 “S”
5 “S” Japanese English
1 S Seiri Sort out unnecessary items in the workplace
and discard them.
2 S Seiton Arrange necessary items in good order.
3 S Seiso Clean your workplace thoroughly so that
there is no dust on floors, machines and
equipment.
4 S Seiketsu Maintain high standards of housekeeping at
workplace at all times.
5 S Shitsuke Train people to follow good housekeeping
disciplines.

3. 5S- Objectives
1. Improve Housekeeping
2. Individual Ownership
3. Beautify by Simple Means
4. Productivity Improvement by
saving time, space etc.
5. Provide foundation for continuous
improvements
3

4. 5S - Principles
1. Elimination of Waste
2. Team Work
3. Attack Root Cause
4. Sustain the movement
5. Human being is not Infallible
4

8. Seiri = Sorting
Frequency of use Storage Method
*Things you have not used
in the past one year
Throw them out
*Things you have used once
in the last 6-12 months
Store at distance OR
Keep in store
LOW
*Things you have used only
once in the last 2-6 months
Store it in central place
in your zone
*Things used more than once
a month
Store it in central place
in your zone
HIGH *Things used once a week Store near the workplace
*Things used daily or hourly Store near the workplace
Organization
8

9. Seiri = Sorting Identifying Unnecessary
1. Parts & Work in Process (WIP)
• Stock of rejected items
• Items accumulated over period for rework
• Material awaiting disposal decision
• Material brought for trial, still lying even after trial
Contd..
9

10. Seiri = Sorting Identifying unnecessary
2. Tools, Toolings
• Toolings brought for trial, Currently not in use
• Worn out bushes, liners, toggles etc. Lying unattended
• Broken tools, bits indisposed
3. Shelves and Lockers
• Shelves and lockers tends to collect things that nobody
ever uses , like surplus, broken items etc.
Contd..
10

11. Seiri = Sorting Identifying unnecessary
4. Walls and Bulletin Boards
• Old out-dated notices which have lost their relevance
• Posters or bulletins on wall
• Remains of torn notices, Cell tape pieces
5. Computer Hard Disk
Many unwanted, outdated, temporary files pile up
Contd..
11

12. Seiri = Sorting Dealing with papers
How to reduce papers on
your table ?
1. Make a single pile of papers
2. Go through them and sort in
following categories
a) Immediate action
b) Low priority
c) Pending
d) Reading material
12

13. FPP – Fixed Point Photography
(Before & After)
 Fix the views of every zone ( 1 to 3 views)
 Capture picture (photo) from the same point every
time
 Get suggestions from zonal members & Improve the
zones continuously
 Capture pictures (photos) every month
 Arrange the photos in chronological order
 Arrange competition
13

14. XYZ Industries - Surrounding Area
Status in Jan.2012
100 Sq. M Area
made free
from removing
unwanted
material
Status in Feb.2012
05.02.2012
20.01.2012
One Cutting m/c shifted in this area
which was previously infront of Office
Status in March 2012
Arranged Two
Welding m/c in
this area
Status in May 2012
28.05.2012

15. WPP – Worst Point Pictures
(Before & After)
 Unsafe conditions
 Excess / insufficient light
 Open / loose electrical joints
 Hanging wires, improper parts, accessories
 No guards for M/cs, Moving parts, Elect. panels
 Mixed material
 Obsolete items / tools / dies / gauges / docs
 Wet floor
 Out of reach points for cleaning
15

16. Steps for doing SEIRI
Sr What to Do? Who Does it?
1 Identify the Coordinator CEO / Plant Head
2 Identify the Zones Plant Head / Coordinator
3 Identify the Zonal Coordinators Plant Head / Coordinator
4 Identify the Red Tags Holding area Coordinator
5 Define the Red Tag Plant Head / Coordinator
6 Establish criteria for Red Tag CEO / Plant Head
7 Establish frequency for doing Red Tag CEO / Plant Head
8 Do the Red Tag All people
9 Identify the Review committee CEO / Plant Head
10 Review the Red Tagged Items & Record Review committee
16

23. PLANT LAY- OUT

24. RAW MATERIAL HANDELING
INSTRUCTION
RAW MATERIAL STORAGE
WITH RACKWISE
IDENTIFICATION,COLOR
CODE,SPECIFICATION

25. A TYPICAL LAYOUT OF AN OFFICE TABLE DRAWER
A PLACE FOR EVERY THING
AND
EVERY THING IN IT’S PLACE

26. RECORD ROOM
BEFORE
AFTER

27. FILE CABINETS
(inside view)

28. Matching colour for easy identification

29. FILE CABINET

30. PLACE FOR EVERYTHING & EVERYTHING IN IT’S PLACE
Back to Home Page

31. LAYOUT BOARD BAY IDENTIFICATION

33. Clear Identification

34. STORAGE IN ENGG.STORES

38. CENTRALIZED
OIL STORAGE
SYSTEM

40. Practice : 5 S
 Identify 5 S Coordinator, Zones, Zonal
Coordinators & Review Committee.
 Display area of zones, photographs of Zonal
coordinator and his team members at appropriate
place in the zone itself.
 Identify Red Tag holding area, define Red Tag,
establish criteria for Red tag & frequency.
 Do the Red Tag as planned, review & record.
40

42. 5M
4.5M
4M
1.3M
Toilet
2.4M
OFFICE
PRESS
12M
9
M
12M
9
M
9
M
8.5M
6
M
5M
3
M
2.5M
QA
SPOT WELDING
&
RECEIVING
6M
9
M
9
M
PACKING
W/C
W/C
W/C
21.5M
8
M
17.5M
Main
Gate
CO2 WELDING

43. Red Tagging Campaign
Zo
ne
No.
Zone Name
Red Tag
Found
Total
Pending
Tags
Red Tag
Found
Total
Pending
Tags
Red Tag
Found
Total
Pending
Tags
Red Tag
Found
Total
Pendin
g Tags
01 Office 16 00 04 00 05 02 4 0
02 Press 13 02 06 01 06 04 4 0
03 Co2 Welding 14 03 05 00 05 04 3 0
04 Spot Welding 12 01 03 00 04 03 4 0
05 Packing & Disp. 14 04 03 02 03 03 3 0
06
Surrounding
Area
09 00 03 01 03 02 02 0
Total 78 10 24 04 26 18 20 0
16
13 14
12
14
9
4
6 5
3 3 3
5 6 5 4 3 3
4 4 3 4 3 2
Zone 01 Zone 02 Zone 03 Zone 04 Zone 05 Zone 06
1st 2nd 3rd 4th

44. Red Tagging Campaign
Zone
No.
Zone Name Red Tag Found
Red Tag Cleared Red Tag pending
(16 Mar 2012)
Total Pending
Tags
(Cumulative)
01 Office 3 3 00 0+2 =2
02 Press 3 3 00 0+7=7
03 Co2 Welding 3 2 01 1+7=8
04 Spot Welding 2 2 00 0+4=4
05 Packing & Disp. 5 3 02 2+9=11
06 Surrounding Area 2 1 01 1+3=4
Total 18 00 36

45. LEAN SLOGAN
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

46. 1S, 2S & 3M
Training
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

47. 1S, 2S & 3M
Internal Training
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

48. Zone Leaders Training Conducted by
Mr. Naresh Chauhan
Agenda: Motivation for 2S & 3M activity
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

49. Training Conducted by
Mr. Tarun Gera
Agenda: FIFO & STD. PACKING
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

50. Training Conducted by
Mr. G.S. Joshi
Agenda: KAIZEN Training to M/c Operaters & Q.C
Inspectors
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

51. PACKING & DESPATCH
ROLLING, TAPPING & W.I.P.
AREA
TOOL ROOM & TOOL DIE AREA
FRONT VIEW OFFICE &
SURROUNDING AREA
FORGING & SECONDARY
SECTION
List of Zones & Zonal Co-Ordinators
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”
WIRE STORAGE & Q.C LAB AREA
SCRAP YARD

52. PLANT HEAD
Mr.Tapan Dey
5S COORDINATOR
Mr.Naresh Chauhan
LEAN COORDINATOR
Mr.Bharat Bhushan
5 S
Implementation
Team
ZONE-1
COORDINATOR
Mr.Bharat Bhushan
ZONE-2
COORDINATOR
Mr.Tarun Gera
ZONE-3
COORDINATOR
Mr.Prempal
ZONE-4
COORDINATOR
Mr.Vishvnath
ZONE-5
COORDINATOR
Mr.Vinod Mishra
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”
ZONE-6
COORDINATOR
Mr.G.S. Joshi
ZONE-7
COORDINATOR
Mr.Mukesh

53. ZONE – 1
Office and Surrounded Area
Mr. Amit Arora Mr Jagdish Mr. Meharbaan
Team Member Team Member Team Member
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”
Mr. Bharat Bhushan
Zone Cordinator-1

54. ZONE - 2
Packing & Dispatch
Mr.Tarun Gera
(Zonal Coordinator Zone – 2)
Miss Rajvinder Kaur Mrs. Nidhi Mrs Beena Mrs.Jamnotri
Team Member Team Member Team Member Team Member
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

55. ZONE - 3 Rolling, Tapping & W.I.P. Area
Mr. Prempal
(Zonal Coordinator Zone – 3)
Mr Baldev Mr Tiwari
Team Member Team Member
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

56. ZONE - 4
Forging & Secondary Section
Mr.Vishvnath
(Zonal Coordinator Zone – 4)
Mr Ekansh Mr Shailender Mr Rameshwar
Team Member Team Member Team Membe
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

57. ZONE - 5
Tool and Tool store Area
Mr.Vinod Mishra
(Zonal Coordinator Zone – 5)
Mr Ranjay Mr. Satveer
Team Member Team Member
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

58. ZONE - 6
Wire Store & Q.C. Lab Area
Mr. G.S. Joshi
(Zonal Coordinator Zone – 6)
Mr . Keshav Mr. Viney Pandey
Team Member Team Member
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

59. ZONE - 7
Scrap yard
Mr.Mukesh
(Zonal Coordinator Zone – 5)
Mr. Anuj Pawar Mr. Rameshwar
Team Member Team Member
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

60. Red Tagging Campaign
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

61. Red Tagging Campaign
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

62. Zone wise WPP
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

63. Zone wise WPP
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

64. Zone wise WPP
“LEAN की सोच, हमारी सोच रहती है हर पल,
BELMAKS में कर लेते, ममलकर समस्या का हल!”

73. Thank you